3d frp pipes

Abstract

Methods and articles of manufacture are disclosed for pipes and Architectural shells and/or Panels (AP) of desired shapes, sizes, and curvatures that can be manufactured onsite or offsite. The disclosed pipes, Architectural shells and Panels, which use resin-impregnated fabrics in combination with spacer sheets, are easy to manufacture, inexpensive, fast to produce, and can easily be repaired, reinforced and refurbished.

What is claimed is: 
     
         1 . A method of constructing a pipe, onsite or offsite, the method comprising:
 providing a mandrel with substantially same or similar surface geometry as the desired pipe;   wrapping at least a first layer of resin-impregnated 2D fabric over and around the mandrel to cover a desired area of the mandrel;   wrapping at least one layer of resin-impregnated 3D fabric over the first layer of resin-impregnated 2D fabric;   allowing the resin-impregnated 3D fabric to at least partially cure; and   wrapping at least a second layer of resin-impregnated 2D fabric over the at least one layer of resin-impregnated 3D fabric;   removing unified combination of fabric layers from the mandrel.   
     
     
         2 . The method of  claim 1 , wherein the wrapping of the first and/or the second 2D fabrics is prformed overlappingly. 
     
     
         3 . The method of  claim 1 , wherein end of the wrapped 3D fabric is overlapping or is butt-joined. 
     
     
         4 . The methd of  claim 3 , wherein the method includes an additional application of a release agent to the mandrel. 
     
     
         5 . The method of  claim 1 , furthere including an additional step of wrapping a plastic/nylon sheet over the mandrel prior to other wrappings. 
     
     
         6 . The method of  claim 1 , wherein the 3D fabric is an expanding or a non-expanding spacer sheet. 
     
     
         7 . The method of  claim 1 , wherein one or more of the wrappings include multiple complete turns around the mandrel. 
     
     
         8 . The method of  claim 1 , wherein the 3D fabric is also filled with filler material. 
     
     
         9 . The method of  claim 8  where the filler material is foam, rubber, or concrete. 
     
     
         10 . The method of  claim 1 , further including application of pressure or vaccum to the assembly while being cured. 
     
     
         11 . The method of  claim 1 , wherein the mandrel is either an existing object, a rigid structure, or is an inflatable bladder or a combination thereof. 
     
     
         12 . The method of  claim 1 , wherein at least one additional layer of non-3D-fabric spacer sheet is utilized. 
     
     
         13 . The method of  claim 1 , wherein any desired combination or permutation of resin-impregnated 2D fabric layers and resin-impregnated 3D fabric layers is formed. 
     
     
         14 . The method of  claim 1 , furthere including an additional step of applying finish coatigs to an exterior and/or interior surface of the pipe. 
     
     
         15 . The method of  claim 14 , wherein the coatigs include paint, abrasion-resistant, chemical-resistant, fire-proofing materials and/or decorative particles. 
     
     
         16 . The method of  claim 1  wherein the first resin-impregnated 2D fabric is wrapped over at least a part of the mandrel and the 3D fabric layer is wrapped over at least a part of the first resin-impregnated 2D fabric layer and the second resin-impregnated 2D fabric is wrapped over at least a part of the 3D fabric layer. 
     
     
         17 . The method of  claim 1  wherein cross-sectional shape and/or size of the mandrel is or is not the same along the length of the mandrel.